Catalyst EX, since version 4.2, has the ability to section a model that exceeds the width of the build chamber, the X axis. It’s a simple option under the Orientation tab. This model is shown in the build chamber of an Elite printer, 8” x 8” x 12”, and exceeds the width at 8.75”.

In previous versions you would need to section the model in your CAD package and process two different files. However, they have added a new check box labeled Section part. If you select this option the view shifts to a top down orientation like this:

And you can see the overhang on the right side. You will also notice a white line that runs parallel to the Y axis, this is where the model will be cut. You can move the cut line to anywhere within the build chamber by simply clicking where you want the cut made. This allows you to avoid details that may be distorted or otherwise damaged by the cut. In this case I’ll cut to the right of the mounting holes so the bolt center distance remains the same.

Once you have decided on the cut line simply click Process STL and Catalyst will cut the model, leaving a mating surface that prevents misalignment, and process the left half as normal.

If you are happy with the orientation now click Add to Pack to put the left half into the current pack. Then go back to the Orientation tab and click the button on the right that says Process Right Section. This will import the right side of the model that was sliced off in the same orientation it was before sectioning.

Now just click Process part again and Catalyst will prepare this part for printing by adding supports and creating the CMB file.

In this case both parts won’t fit on one tray but if yours do then you can add the right section and print the parts. Once you have both parts you can bond them together with any solvent or adhesive that will work with ABS plastic.

There are a couple of limitations to this. First, you are only allowed to section the part along the Y axis, meaning your model can only exceed the width of your printers envelope in the X axis (8” for Elite, 768 and uPrint printers and 10” for the 1200 printers). Second, you are limited to one cut, meaning your model can only be up to twice as wide as the printer (actually a little less due to the mating surface). Even with these limitations it greatly increases the capacity of the existing printers. If you need still larger models you may be interested in the Fortus line of production machines, with build chambers up to 36” x 24” x 36”,a s well as additional materials.